Flashless welding method and apparatus

ABSTRACT

A method and apparatus for welding two separate ends of an extrusion or two separate extrusion ends to form a flashless extrudate or gasket by having a first and a second mold for supporting and clamping the extrusion ends, and a spacer bar for positioning the extrusion ends to a location within the mold. A heating element elevates the temperature of the extrusion ends to a welding condition, and a clamping device is used for securing the extrusion ends. A flashless welding operation results by inserting and clamping at least one heated extrusion end into a welding mold until an acceptable contact pressure is obtained against the opposing heated extrusion end.

FIELD OF THE INVENTION

The present invention concerns both methods and apparatus relating tothe welding of various materials together generally, and morespecifically, it relates to the improvements in the welding process thatresults in a flashless connection between separate articles or oppositeends of a single article.

BACKGROUND ART

Several different methods of extruding thermal plastics are well knownin the industry, including methods for both cold and hot feed extrusion.There is an infinite number of extrusion profiles that can be extrudeddepending on the shape and contour of the particular die used in theextrusion process. The four most common extrusion profiles are tubing,channel, cord and bulb seals.

Finished extruded material can be made into continuous rolls of varyinglength, generally referred to in the industry as extrudate. The lengthof the extrudate roll is typically specified from a customer's stockorder. Alternatively, the finished extruded material can be formed tomake individual parts that often resemble an endless loop or ring,typically referred to by those skilled in the art and hereinafter as agasket, a continuous gasket, or an endless gasket. An endless gasket isformed by welding the opposite ends of a single piece of extrudedmaterial together. The end products whether originating form extrudateor an endless gasket can include residential weather seals, automotiveweatherseals and gap fillers, major appliance seals, construction seals,architectural glazing seals, large diameter pipe seals, and variousseals used in equipment or machinery.

During the manufacturing of an endless gasket, extruded material isfrequently cut to length for a particular application and then weldedtogether end-to-end to form an infinite number of shapes and sizes. Themost common endless caskets form a rectangular or circular pattern.

It is not uncommon for a break to occur in the extrudate for any numberof reasons, including fatigue or stress on the extrusion, depletion ofraw materials making up the compound, machine break-down, or operatorneglect during the manufacturing process. Since the extrudate is sent inrolls conforming to a customer's specified length, a splice isfrequently needed in order to make the material, once again, continuous,which avoids the creation of scrap because the extrusion length is tooshort to fill the customer's order. A splice is also needed in theendless gasket product in order to connect two ends of a single extrudedpiece of material in order to form a continuous ring.

Therefore, a joining process is needed in order to unite opposite endsof a single article to make an endless gasket or to unite separatepieces of extruded material in order to form an extrudate. Heat isapplied through a heating element during a welding operation at theextruded material ends. During the joining process a splice resultsbetween the ends of two separate extrusions or the two ends of thesingle extrusion. After the welding operation, the resulting splice canleave an undesirable seam or flash, which is not part of the finishedproduct. This flash is particularly undesirable in extruded profilesthat perform a sealing function. In addition, the flash generates extracost to the product by requiring an additional deflashing operation,either manually by an operator or a mechanical trimming operation. Aswell, trimming the flash can propagate tears, which weakens the weldedjoint

The cost associated with trimming and removing flash material from anextruded product can be significant because of the additional operationsand/or labor. This cost can be compounded in scrap that is produced whenthe flash removal results in trimming important parts of the finishedproduct through operator error or machine overshoot in mechanicaltrimming operations.

What is needed is an improved method and apparatus that allows for astrong flashless connection between separate ends of an extrusion toform an endless gasket product, or between separations in extrudedmaterial to form a continuous extrudate product.

SUMMARY

The present disclosure is directed to an improved system for forming aseamless weld between two ends of extruded material, typically thermalplastics, such as and including without limitation,Acrylonitrile-Butadiene-Styrene (“ABS”), Polyvinyl Chloride Plastic(“PVC”), Polystyrene, Polyolefinic materials such as polypropylene, andpolyethylene, Thermoplastic Elastomers (“TPE”) and other similarlystructured composites. The ends are joined to form either an extrudateor endless gasket.

In one exemplary embodiment, first and second extrusion ends are equallyspaced against a spacer bar then secured within a clamp and positionedwithin a corresponding mold. The spacer bar is then retracted, creatinga void for the insertion of a heating element. After a prescribedtemperature is reached, the heating element is removed and the first andsecond molds are pushed together, where the molds freely pass over therespective extrusion ends. Once the molds assume a facial contactposition, one clamp advances one extrusion end to a mating position,contacting the opposing extrusion end, while the opposite clamp remainsstationary having a secured hold on its corresponding extrusion end.After the extrusion ends are in a contacting position, the molds areclosed on the still molten material at the weld joint or splice. Thiscompression action either prevents the flash from forming or reforms theflash back into the body of the extrusion cross section. The tooling isthen released in conjunction with the clamps moving to an open positionfor the removal of a now continuous flashless product.

The described process can also be used for attaching corner jointsbetween extrusion ends. Similarly, the corner joints are securely formedin a flashless type connection, resulting in an endless gasket product.

In another exemplary embodiment, the first and second extrusion ends areno longer equally spaced about their respective molds. Instead, thespacer bar allows one of the ends to be offset, extending to a distancegreater than the opposing extrusion relative to the face of the mold.The offset distance is controlled by the location of the spacer bar,which acts similar to a physical stop in a fixture. In this particularembodiment, the molds now perform the clamping function previouslyexecuted by a separate set of clamps. This is accomplished by keepingone of the clamping molds stationary, while the opposite clamping moldis a mobile mold capable of movement. Within the cavity of the mobilemold is the extrusion end having the greater offset, and at this point,the mold acts as a clamp and securely grips the offset extrusion end.The opposing stationary mold, although in contact with the secondextrusion end forming a secure attachment, provides for movement of thesecond extrusion end.

The mobile mold is then advanced toward the stationary mold, plungingthe offset end into the stationary mold making contact and adhering tothe opposite extrusion end, while driving it back into the stationarymold. Just prior to the plunging operation the stationary mold waspreheated and continues to be heated until the extrusion ends are incontact. After extrusion contact, the stationary mold is cooled, therebyimproving both the weld strength and appearance while eliminating flash.The molds are then opened for the removal of a now continuous flashlessproduct

In another embodiment, the heating element and spacer bar are combined.This eliminates a processing step and associated manufacturing costs.

In another exemplarily embodiment, a heater mold is located to aproximal side of a clamping mold. The heater mold coacts with astationary clamping mold for receiving the opposing extrusion end andaids in forming a strong flashless seam between the two ends. The heatermold similarly clamps the two extrusion ends together after contact andis designed to cool in order to enhance the integrity of the connectionbetween the two ends. The heater mold provides more control over thethermal processing of the extruded material by regulating the heatingand cooling rates after the extrusion ends are joined. In addition, theheater mold reduces the fluctuation in temperature as the extrusion endstransition to a joining position, thus increasing the strength andseamless appearance in the connection.

Another aspect or feature associated with the use of a heater mold isthe elimination of a thermal swelling phenomena that occurs after anextrusion is heated and cooled. It is not unusual for the resultingextrusion to grow because of swelling that occurs from the heating andcooling of the material inside the molds. By under sizing the heatermold cavity to a percentage less than the extrusion's desiredcross-sectional area, allows the extruded material to retain the desiredspecification size typically in existence prior to heating.

In another exemplarily embodiment, a heater mold is locatedsymmetrically about both clamping molds. After each respective extrusionend is loaded into the clamping molds, the heater mold remains spatiallylocated from the extrusion ends at a prescribed distance. The distancebeing a value that still allows for free movement of the extrusion ends,but provides a position for efficient heat placement. After the heatermold is heated, or alternatively, hot air is directed into the moldbetween the two extrusion ends, the extrusion ends begin to melt. Bothclamp molds are capable of movement and at this point advance theextrusions in concert until contact occurs. The heater mold is thencooled and the molds are then opened for the removal of a now continuousflashless product.

Another aspect of an exemplary embodiment includes the heating of theextrusion ends by utilizing heater bar sleeves, which encompass thejoining sections of the extrusion ends. The heating sleeves are slightlyoffset from the extrusion profile and heat the extruded material along aportion of the extrusion ends. Each sleeve is oversized but follows theprofile of the extrusion ends and are spaced to a controlled distancefor optimizing the heating process. The heater bar sleeves can be usedalone or in combination with a heater bar. After the extrusion endsreach a prescribed temperature, the sleeves are retracted and theextrusion ends are advanced into a heating mold until joining contact isachieved. The heater mold is then cooled and the molds are then openedfor the removal of a now continuous flashless product.

These and other advantages and features of the exemplary embodiments ofthe invention are described in detail in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an elevation view of the welding system of a first embodimentin an extrusion end loading position;

FIG. 1B is an elevation view of the welding system of FIG. 1A in aheating position;

FIG. 1C is an elevation view of the welding system of FIG. 1A in aclamping position;

FIG. 1D is an elevation view of the welding system of FIG. 1A in awelding position;

FIG. 2A is an elevation view of the welding system of a secondembodiment for making a corner weld with the extrusion ends beingpresented in a loading position;

FIG. 2B is an elevation view of the corner welding system of FIG. 2Awith the extrusion ends in a heating position;

FIG. 2C is an elevation view of the corner welding system of FIG. 2Awith the extrusion ends in a welding position;

FIG. 3A is an elevation view of the welding system showing a thirdembodiment with the extrusion ends loaded and spaced in an offsetposition;

FIG. 3B is an elevation view of the welding system of FIG. 3A withextrusion ends in a heating position;

FIG. 3C is an elevation view of the welding system of FIG. 3A with theextrusion ends in a welding position;

FIG. 3D is an elevation view of the welding system of FIG. 3A with themolds positioned in an extrusion unloading position;

FIG. 4A is an elevation view of the welding system showing a fourthembodiment comprising a separate heater mold;

FIG. 4B is an elevation view of the welding system of FIG. 4A with theextrusion ends in a heating position;

FIG. 4C is an elevation view of the welding system of FIG. 4A with theextrusion ends in a welding position;

FIG. 5A is an elevation view of the welding system showing anotherembodiment with a heating mold symmetrically located about the extrusionends;

FIG. 5B is an elevation view of the welding system of FIG. 5A showingthe extrusion ends encompassed within the heating mold in a weldingposition;

FIG. 6A is an elevation view of the welding system showing an embodimentemploying a heating mold and heating sleeves in position forencompassing the extrusion ends;

FIG. 6B is an elevation view of the welding system of FIG. 6A with theextrusion ends in a heating position between a pair of heater barsleeves;

FIG. 6C is an elevation view of the welding system of FIG. 6A where theheating bar and heating bar sleeves are retracted for advancement of theextrusion ends into the heating bar; and

FIG. 6D is an elevation view of the welding system of FIG. 6A showingthe extrusions encompassed within the heating mold in a weldingposition.

DETAILED DESCRIPTION

FIG. 1A is a schematic depiction of an extrusion welding system 10having a first and a second extrusion end, 11 and 12, respectivelyplaced in a loading position. The extrusions represent the ends of twoarticles or the opposite ends of a single article. The extrusion mayinclude a gasket having thermal plastic properties requiring aconnection to form an endless flashless product. Alternatively, theextrusions may connect two separate extrusions together to form afinished product having separate opposite ends, or include forming anextrudate that requires a connection between two separate extrusions toform a continuous roll stock.

The welding system is capable of seamlessly welding extrusioncompositions typically classified as thermal plastic material, such asand including without limitation, Acrylonitrile-Butadiene-Styrene(“ABS”), Polyvinyl Chloride Plastic (“PVC”), Polystyrene, Polyolefinicmaterials such as polypropylene, and polyethylene, ThermoplasticElastomers (“TPE”) and other similarly structured composites, but couldalso include any other material or compound having similar chemicalproperties. The welding system is also capable of seamlessly welding anunlimited number of geometrical profiles by designing the extrudedmaterial's profile into the welding system molds (mold adaptation),however the extrusion will be represented in the following Figures asbeing cylindrical for simplicity.

FIGS. 1A-1D depict a preferred embodiment having pair of extrusion molds21 and 22, substantially symmetrically located about an imaginaryvertical axis depicted as Y-Y. The placement of the first and secondextrusion ends are to a point of contact with a spacer bar 13, whichacts as a physical stop for the extrusion ends at their joining endsrepresented by 11 a and 12 a, as best seen in FIG. 1B. At this point,the molds 21 and 22 are not completely closed over the extrusions, butinstead comprise a gap of approximately 0.030″ with their correspondingextrusion end.

After the extrusion ends are positioned, a static clamp 25 and moveableor mobile clamp 26 are closed securing the extrusion ends to a fixedfirst position “A”, as shown in FIGS. 1A and 1B. The spacer bar 13 isthen retracted creating a void for the insertion of a heating element15, as shown in FIG. 1B. The heating element can be a number ofdifferent devices known by those skilled in the art of extrudingmaterials. Some heating element examples can include, laser heaters,thermal electric resistive heaters, and hot air or gas heaters.

Although FIG. 1B depicts some distance between the first and secondextrusion ends and heating element 15, depending on the material andheat requirements it is possible that the extruded material is capableof being in direct contact with the heating element. After anappropriate melting temperature is reached, having an approximate rangebetween 150-300 degrees centigrade for a typical thermal plastic, theheating element 15 is removed and the molds are advanced to a secondfacial contact position, freely passing over the extrusion in closeproximity as shown in FIG. 1C.

FIG. 1D depicts the joining process where the first and second extrusionends become welded together to form a continuous flashless connection.Joining of the extrusion ends is achieved by advancing the moveableclamp 26 from a first position “A′” shown in FIG. 1C to a secondposition directed toward the second mold 22 as depicted in FIG. 1D.Prior to physical contact between the moveable clamp 26 and mold 22, aacceptable resistance pressure 30 is attained, indicating that thecontact pressure between the first and second extrusion joining ends areat level for forming a connecting weld between the two extrusions shownat point “C” in FIG. 1D. An acceptable pressure 30 is one that allowssufficient contact for welding thermal plastics. Such pressure isdetermined by adjusting the pressure applied to the clamps until anadequate bond is achieved. This pressure is therefore, empiricallydetermined. Once the acceptable resistance pressure 30 is attained, theadvancement of the moveable clamp 26 stops (represented by position “B′”in FIG. 1D) leaving a slight gap between mold 22 and moveable clamp 26.Molds 21 and 22 are then closed, forming a clamping connection betweenthe two heated extrusion ends. The resistance pressure 30 can bemeasured by a number of different devices recognizable to those skilledin the art, such as pressure transducers, strain gauges, and linearvariable displacement transducers (“LVDT”).

After the first and second molds cool to a predetermined temperature,typically ranging from 60 to 80 degrees centigrade for most thermalplastics, the molds are opened and the continuous flashless extrusion iscured for removal.

Referring now to FIGS. 2A-2C is a separate preferred exemplaryembodiment representing the above describe flashless welding techniquefor joining a first and a second extrusion end 11 and 12 in a cornerconnection. A corner connection is desirable in applications requiring aseamless connection at a prescribed nonlinear angle represented by “θ”.One of the most popular applications is for window molding or gasketwhere θ is equal to 90 degrees. However, it should be understood bythose skilled in the art that θ can be at any angle.

Returning to FIG. 2A, the first and second extrusion ends are supportedby molds 21 and 22, and are in contact with a spacer bar or stop 13 at aspecified first distance “A”. The molds are at a first position “A′”that is substantially symmetrical about an imaginary axis represented byY-Y. Once the extrusions are positioned against the spacer bar 13, thebar is retracted allowing for the advancement of a heating element 15between the first and second extrusion ends, 11 and 12, as shown in FIG.2B.

After the heating element elevates the temperature of the extrusion to amelting temperature, typically ranging between 150-300 degreescentigrade for most thermal plastics, the heating element is removed.Shortly thereafter, the molds are advanced to position “A″” in closeproximity to the first 11 and second 12 extrusion ends that are alsoadvanced by clamps (not shown) to a point of contact as depicted in FIG.2C. In concert with the aforementioned mold movement is advancement of aheating mold 20, which is moved forward until achieving a closeproximity with the joining ends 11 a and 12 a of the extrusions. Afteran acceptable resistance pressure is obtained, the advancement of theextrusions and molds stop, allowing the molds to cool. After theprescribed cooling temperature is reached, the molds and clamps areopened allowing the continuous flashless corner mold to be removed. Thecombination of plunging, clamping, and cooling the molten extrusionmaterial together prevents a flash from forming on the extrusion, and/orforces any excess material to be formed back into the body of theextrusion.

Another preferred exemplary embodiment is shown in FIGS. 3A-3D. In thisembodiment, the extrusion ends 11 and 12 are no longer locatedsymmetrically about the vertical axis Y-Y. Additionally, the first andsecond molds 21 and 22 are clamping molds replacing the need forseparate clamping apparatus.

Spacer bar 13 locates the first 11 and second 12 extrusions at an offsetdistance “X′” and “X″” respectively, as depicted in FIG. 3A. The offsetdistances vary based on material type and size, however, for a ½ of aninch diameter extrusion, distances X′ and X″ provided a sufficientlystrong welded connection at distances ¼ and ½ of an inch, respectively.For most thermal plastic materials, the heating element 15 should bethermally elevated in order to bring the extruded material to a meltingtemperature, approximately ranging between 150-300 degrees centigrade,varying only the duration of exposure based on the size of theextrusions. It should be understood by those skilled in the art that thegreater the size or surface area of the extrusion ends, the greater theheating exposure duration.

Referring now to FIG. 3B, once the offset locations of the extrusionends are positioned, the spacer bar 13 is retracted Mold 21 now clampsits respective extrusion end, while the second mold 22 remains in closeproximity to the second extrusion end leaving a 0.030″ therebetween forfree movement over the second extrusion end 12. The heating element 15is then positioned between the extrusion ends for thermal processing.

After a prescribed temperature is achieved at joining ends 11 a and 12a, the heating element is removed and clamping mold 21 is advanced fromposition “A” in FIG. 3B, thereby plunging the first extrusion end 11into the second stationary mold 22. The advancement of first clampingmold 21 ceases once the prescribed resistance pressure 30 is attained,which is represented by position “A′” in FIG. 3C. The acceptableresistance pressure indicates that the contact between the first 11 aand second 12 a extrusion joining ends is at a level for a connectingweld represented by splice point “C” in FIG. 3C. Stationary mold 22 nowclamps the corresponding extrusion ends for a duration that allows theextrusion ends to cool to a temperature below a softening point of thematerial, which is typically around 65 degrees centigrade for mostthermal plastics. The plunging of the molten extrusion end into theopposing mold along with the continued compression resulting from theclamping until a cooling temperature is reached prevents any flash fromforming and/or reforms any potential flash material back into the bodyof the extrusion, thus enhancing both the integrity and seamlessappearance of the welded connection.

After the joining process of FIG. 3C, a continuous flashless extrudateor endless gasket 40 is considered cured and ready for removal. As such,molds 21 and 22 are raised allowing the ejection of the single pieceflashless extrusion 40 as shown in FIG. 3D. After removal the processreturns to the operation described and shown in FIG. 3A.

Referring now to FIGS. 4A-4C is a preferred embodiment having a separateheater block mold 23 located to a proximal side 22 a of stationary mold22. A first 11 and a second 12 extrusion end are loaded in the molds 21,22, and 23 and are similarly spaced about spacer bar 13 in either asymmetrical or offset position. Moveable mold 21 then securely clampsfirst extrusion 11. The spacer bar 13 is then retracted allowing theinsertion of heating element 15, which thermally conditions extrusionjoining ends 11 a and 12 a for the requisite duration, while the heaterblock mold preheats to a temperature approximately ranging between150-300 centigrade for a typical thermal plastic material.

After the designed temperature is reached, the heating element isremoved and the moveable mold 21 advances from position “A” in FIG. 4B,plunging the first extrusion 11 into stationary mold 22 until theprescribed contact pressure 30 with the second extrusion 12 is reached.FIG. 4C represents achieving the prescribed contact pressure 30 asoccurring at position “A′”. The heater mold 23 and stationary mold 22then clamp the extrusion ends. The heater mold was preheated topredetermined temperature prior to the plunging operation. Thetemperature in the heater mold, for example should be elevated toapproximately 200 degrees centigrade for a typical thermal plasticmaterial. The incorporation of the heater mold provides more controlover the thermal processing of the extruded material during the weldingoperation by regulating the heating and cooling rates before and afterthe extrusion ends are joined. In addition, the heater mold reducesfluctuation in temperature as the extrusion ends transition to a joiningposition, thus increasing the strength and seamless appearance inbetween the extrusion ends. Further advantages are obtained by using aheater mold, such as the elimination of a thermal swelling phenomenathat occurs after an extrusion is heated and cooled. It is not unusualfor the size of the resulting extrusion to grow because of swelling,which occurs from the heating and cooling of the material inside themolds.

Under sizing the heater mold cavities from 95% to 99.9% of specifiedextrusion's cross-sectional area eliminates post-thermal swelling. Ithas been found that a 3% decrease in cavity size or 97% of the desiredextruded cross-sectional area to be the preferred reduction. Forexample, a cylindrical profile extrusion having a desired finishedspecification diameter of ½″ or 0.500″, requires the correspondingheater mold cavity to be sized between 0.475″ and 0.4995″, andpreferably 0.485″.

After the heating process is complete, the now single flashlessextrusion is allowed to cool before removal from the welding systemmolds. The combination of plunging, clamping, and cooling the moltenextrusion material together prevents a flash from forming on theextrusion, and/or forces any excess material to be formed back into thebody of the extrusion.

Encompassing FIGS. 5A and 5B is a separate preferred embodiment, inwhich a heater mold 23 is symmetrically located between clamping molds21 and 22. In a first position shown in FIG. 5A, a first 11 and a second12 extrusion end is loaded within molds 21 and 22, with first joiningends 11 a and 12 a of the extrusion ends only slightly penetratingheating mold 23. Molds 21 and 22 are then securely clamped on theextrusions, while heating mold 23 remains only in close proximity withthe extrusion ends. At such point, heat is applied from the heating mold23 by hot air, resistive heating, laser heating, gas, or any otherconventional method known by those skilled in the art for heatingthermal plastic materials.

Once the extrusion joining ends 11 a and 12 a reach a prescribed meltingtemperature, the extrusions begin to melt, and clamping molds 21 and 22are advanced, pushing the respective extrusions together until theprescribed resistive pressure 30 from contact between the extrusion endsis reached. The heating mold 23 then clamps the ends 11 and 12 togetheruntil the heating and a subsequent cooling process are complete. Themolds are then opened and the continuous flashless extrusion is readyfor removal. The combination of heating the mold, advancing theextrusion ends, and clamping to provide continuous pressure on themolten extrusions until the prescribed cooling temperature is reachedprevents any flash from forming at the connection of the ends and forcesany excess material to be reformed into the body of the extrusion. Thiswelding process enhances both the integrity and seamless appearance ofthe welded connection.

Referring to FIGS. 6A through 6D is another preferred welding systemhaving a pair of heater bar sleeves 31 and 32. The heater bar sleevesreceive and envelop the first 11 and second 12 extrusion ends, as shownthrough FIGS. 6A and 6B. This is accomplished by advancing the extrusionends into the sleeves by progressing first and second clamps 21 and 22to a heating position shown in FIG. 6B.

The heater sleeve can act in place of a heater bar 15 or in conjunctionwith the heater bar as shown in FIGS. 6A-6D. If the heater sleeves areused in combination with the heater bar 15, the sleeve temperature canbe reduced ranging between 150-300 centigrade to melt the extrusion endsalong a linear distance enveloped within the sleeves. Absent the heatingbar 15, the sleeves may require a temperature in excess of 250centigrade.

After achieving a melting point on the extrusion ends, the heatersleeves 31 and 32 and in this embodiment, heater bar 15 are retracted asshown in FIG. 6C. The extrusion ends are now capable of advancing to awelding position within a heater mold 23, as shown in FIG. 6D anddiscussed previously. Advancement of first 21 and second 22 molds ceasesonce a joining pressure 30 is obtained. The extrusion ends are nowwelded and cooled to a prescribed temperature within the heater mold,after which a single piece gasket or extrudate can be removed.

The heating sleeves aid in elevating the temperature over a larger andmore uniform portion of the extrusion ends. As a result, a more uniformweld is formed increasing the overall weld strength. In addition, thecombination of heating the mold, advancing the extrusion ends into aheater mold, and clamping to provide continuous pressure on the moltenextrusion ends until the prescribed cooling temperature is reachedprevents any flash from forming at the connection of the ends and forcesany excess material to be reformed into the body of the extrusion. Thiswelding process enhances both the integrity and seamless appearance ofthe welded connection.

While the present invention has been described with a degree ofparticularity, it is the intent that the invention includes allmodifications and alterations from the disclosed design falling with thespirit or scope of the appended claims.

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 15. An apparatusfor forming a flashless weld between extrusion ends comprising: a) afirst and a second mold for supporting and clamping the ends of at leastone extrusion; b) a locator for positioning the extrusion ends locationwith respect to said molds; c) a heating element for elevating thetemperature of said extrusion ends to a welding condition; and d) aclamping device for securing extrusions during said welding operation;e) whereby flashless welding occurs by clamping and plunging at leastone said extrusion ends into a welding mold until contact is madeagainst said other extrusion end within said welding mold.
 16. Theapparatus for forming flashless weld of claim 15, wherein said weldingmold acts as said heating element.
 17. The apparatus for forming aflashless weld of claim 15, wherein welding occurs by inserting twoextrusion ends into said welding mold.
 18. The apparatus for forming aflashless weld of claim 15, wherein welding occurs by inserting twoextrusions into said welding mold to form a corner weld.
 19. Theapparatus for forming a flashless weld of claim 15, wherein said firstand second molds act as said clamping device.
 20. The apparatus forforming a flashless weld of claim 15, wherein one of said first andsecond molds act as said welding mold.
 21. The apparatus for forming aflashless weld of claim 15, wherein said heating element is agas-heating device.
 22. The apparatus for forming a flashless weld ofclaim 15, wherein said heating element is an electric-resistive-heatingdevice.
 23. The apparatus for forming a flashless weld of claim 15,wherein said heating element is a laser.
 24. The apparatus for forming aflashless weld of claim 15, wherein said heating element acts as saidlocator.
 25. (canceled)
 26. (canceled)
 27. An apparatus for weldingextrusion ends to form a flashless extrusion comprising: a) a first andsecond extrusion end residing in a first position in respective firstand second molds; b) a heating assembly for elevating the temperature ofsaid extrusion ends to a joining condition; and c) a heating moldpreheated to a temperature to facilitate welding said first and secondextrusion ends; d) whereby flashless welding occurs after one of saidfirst and second extrusion ends is advanced towards the other of saidextrusion ends moving said ends into said heating mold until contact ismade between said ends such that closing said heating mold on the endsforms a welding connection therebetween.
 28. The apparatus for weldingextrusion ends of claim 27, wherein said heating assembly comprises apair of heater sleeves.
 29. The apparatus for welding extrusion ends ofclaim 27, wherein said heating assembly comprises a pair of heatersleeves and a heater bar.
 30. The apparatus for welding extrusion endsof claim 27, wherein the cavity of said heater mold is undersized to apercentage of the extrusion's desired size. t.
 31. An apparatus forwelding thermal plastic material comprising: a moveable mold comprisingan opening for supporting thermal plastic material and a facing end, theopening aligned and spaced with a facing end of a forming moldcomprising an opening for supporting thermal plastic material; a heatingelement for heating thermal plastic material in at least one of saidforming mold and said moveable mold; and upper and lower clampingportions in said forming mold that that collectively shape the openingin said forming mold, at least one of said upper clamping portion andsaid lower clamping portion moveably attached in said forming mold thatreduces the size of the opening in said forming mold upon weldingthermal plastic material supported by said moveable mold and saidforming mold that is located during welding within said forming mold.32. The apparatus of claim 31 wherein said openings are cylindricallyshaped.
 33. The apparatus of claim 31 further comprising a spacermoveably located between the facing ends of said moveable mold and saidforming mold, said spacer providing a positioning stop for locating theposition of the thermal plastic to be supported by the openings in saidforming and moveable molds.
 34. The apparatus of claim 31 wherein saidheating element is one of said forming mold and said moveable mold. 35.The apparatus of claim 31 wherein said heating element is both of saidforming mold and said moveable mold.
 36. The apparatus of claim 33wherein said spacer is further constructed to be said heating element.